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DOE OSTI2025

Thermodynamic properties of ZrCl 4 with LiCl, NaCl, KCl, CsCl, MgCl 2 , and UCl 3 for molten salt reactor applications

Here, a set of self-consistent Gibbs energy functions has been developed to describe the thermochemical behavior of the major reactive fission product ZrCl 4 with key components in chloride molten salt reactors (MSRs): LiCl–ZrCl 4 , NaCl–ZrCl 4 , KCl–ZrCl 4 , CsCl–ZrCl 4 , MgCl 2 –ZrCl 4 and UCl 3 –ZrCl 4 . Low ZrCl 4 concentration phase equilibria most relevant to MSR applications have been confirmed via differential scanning calorimetry for NaCl–ZrCl 4 , and X-ray diffraction analysis performed on equilibrated samples of NaCl–ZrCl 4 , KCl–ZrCl 4 , MgCl 2 –ZrCl 4 , and UCl 3 –ZrCl 4 . Within the framework of the modified quasi-chemical model in the quadruplet approximation, extrapolations of pseudo-binary models were generated to represent KCl–MgCl 2 –ZrCl 4 , KCl–NaCl–ZrCl 4 , and MgCl 2 –NaCl–ZrCl 4 , which show agreement with phase equilibria data where available without the use of ternary interaction parameters. The optimized thermodynamic descriptions for these systems and others are available in the open-source compendium Molten Salt Thermal Properties Database – Thermochemical (MSTDB–TC).

CALPHAD↗

DOE OSTI2025

OH density and water vapor concentration gradients during plasma-droplet interactions

Plasma-droplet interactions significantly promote the reactivity transfer of gas phase species from the plasma to the liquid phase. Nonetheless, experimental studies on the impact of droplet evaporation on reactive species generation in such systems remain scarce. We report the spatial distribution of water vapor and OH radical densities around a droplet (∼41 μm in diameter) in He and He-Ar plasma using laser-induced fluorescence. The results reveal a significant gradient in both water vapor and OH radical concentrations near the droplets. Mutiple droplets present in the plasma can lead to a significant accumulation of water vapor and even local quenching of the discharge. The findings are critical for developing a quantitative understanding of plasma-liquid interactions for a broad range of plasma-enabled applications in the liquid phase often involving OH radicals.

42 ENGINEERING↗

DOE OSTI2024

High-Fidelity Arc-Discharge Model for Hydrogen-Plasma-Smelting-Reduction of Iron Ore

Electrification and use of renewable hydrogen is currently a necessity for decarbonizing the iron-and-steel industry. In this regard, hydrogen plasma smelting reduction (HPSR) is a novel pathway that is being explored for reduction of iron ore. HPSR provides several decarbonization merits compared to conventional blast furnaces. Firstly, the use of renewable hydrogen drastically reduces the CO2 emissions compared to the use of coke. Secondly, renewable electricity in the form of a thermal plasma for making reactive hydrogen species (radicals, ions) are more efficient at reducing iron ore compared to neutral H2. Thirdly, a molten product compatible with downstream processes is obtained from the intense heat transfer from the plasma. However, the scale-up of this technology requires fundamental exploration of hydrogen plasma dynamics and its interaction with complex solid material that include phase changing iron-ore and slag. In this work, we present a first principles continuum scale model for thermal plasmas in Ar/H2 gas mixtures typically used for HPSR. The thermal plasma governing equations for mass, momentum and energy with Lorentz force and Joule heating source terms are solved along with electromagnetic equations for electrostatic and magnetic vector potential. Our solver will be based on Pele, a suite of reacting flow solvers designed for advanced scientific computing architectures (Henry De Frahan et al., Proceedings of SIAM Parallel Processing, 13-25, 2024), and will utilize adaptive mesh generation for enhanced resolutions at locations of intense physicochemical interactions. This study will present the impact of Ar to H2 ratios on excited/dissociated hydrogen species concentrations, plasma temperature and conductivity along with the impact of outgassed species (water, metal vapor, O, OH radicals) from ore surface on gas phase chemistry. Furthermore, the heat and species flux to the surface will be quantified as a function of applied voltages in a transferred arc configuration.

hydrogen plasma↗

DOE OSTI2026

Optimization of Annealing for WZ-Phase Removal and Densification in Sb-Doped CdSexTe1-x Solar Cells

The impact of high temperature annealing (HTA) treatments on the performance of Sb-doped CdSeTe solar cells containing a CdSe0.25Te0.75/CdTe front stack and a vapor transport (VT) deposited CdTe:Sb absorber was studied. The HTA treatment of the thermally evaporated CdSe0.25Te0.75/CdTe front stack converts the mixed-phase film into a single zinc blende structure through recrystallization of the photo-inactive wurtzite phase. Subsequently, HTA treatment of the full device stack after vapor transport deposition of CdTe:Sb absorber promotes Se-Te intermixing, reduces voids, densifies the full stack and enhances CdTe:Sb grain growth. Comprehensive characterizations revealed that the combined HTA treatments significantly improved film crystallinity, removed the WZ phase in the front stack, enhanced full-stack densification, reduced defect densities, and enhanced carrier dynamics. With HTA treatments, the open-circuit voltage (VOC) of CdSeTe:Sb devices increased from ~ 400 mV to >= 600 mV, and when combined with optimized CdCl2 treatment, VOC reached 849 mV. The net carrier concentrations (NA-ND) of representative devices were NA-ND = 1.5 x 10^15, 1.1 x 10^15, and 3.5 x 10^14 cm-3 for the no-HTA, moderate-HTA, and optimized high-VOC conditions, respectively. Since the highest VOC corresponds to the lowest apparent NA-ND, , which is similar to a Cu-doped-only CdSeTe solar cell (NA-ND ~= 2 x 10^14 cm-3), the data indicate that improved device performance does not result from increased electrically active Sb; instead, it points to structural improvement as the dominant effect of HTA. The findings demonstrate the potential of HTA treatments to improve the structural and electrical properties of CdSeXTe1-X solar cells.

14 SOLAR ENERGY↗

DOE OSTI2024

Vapor Infiltration Synthesis of Indium Sulfide Magic Size Cluster

The energetically favorable formation of atomically precise clusters, known as magic size clusters, in the solution phase enables a precision nanoscale synthesis with exquisite uniformity. Here, we report the synthesis of magic size clusters via vapor infiltration of atomic layer deposition precursors directly in a polymer thin film. Sequential infiltration of trimethylindium vapor and hydrogen sulfide gas into poly(methyl methacrylate) leads to the formation of clusters with uniform properties consistent with a magic size cluster-In 6 S 6 (CH 3 ) 6 . While an increase in cluster size might be expected with additional sequential infiltration cycles of the reactive In and S precursors, uniform properties consistent with magic size clusters form in multiple polymers under a range of processing conditions. Ultraviolet-visible absorption spectra of In 6 S 6 (CH 3 ) 6 are largely independent of the number of sequential infiltration cycles and exhibit air stability, both of which are attributed to an energetically favorable synthetic pathway that is evaluated with density functional theory.

atomic layer deposition↗

DOE OSTI2025

Phase-field modeling of aging-induced microstructure evolution in pentaerythritol tetranitrate thin films and ramifications for shock initiation

Aging of energetic materials may change performance and affect their safety and reliability, but the relationship between microstructure changes induced by aging and consequent performance changes has not been fully established. This work presents results of phase-field method simulations used to model microstructure evolution of vapor-deposited pentaerythritol tetranitrate (PETN) thin films. Simulated aging is shown to induce grain coarsening and substantial changes of the configuration of porosity in the film: Specifically, we show that porosity tends to concentrate in large pores to a greater degree in aged films, a state that is arrived at by closure or consolidation of small pores. To evaluate the performance of the as-deposited and aged films, we perform two-dimensional hydrocode flyer-film impact simulations that incorporate the phase-field output microstructures directly, permitting us to connect features therein to changes in reactivity, a key metric of energy output for shock initiation. The results demonstrate that declining sensitivity obtained for the simulated aged films can be correlated with the loss of fine-structured pores relatively early in the aging process, while long-term microstructure evolution that gradually alters the shape of large, branching pores is less impactful. Finally, we discuss commonalities and discrepancies between our simulation results and high-throughput initiation experiments on shock initiation of aged PETN thin films.

36 MATERIALS SCIENCE↗

DOE OSTI2025

In situ atomic-resolution imaging of water vapor–driven multistep oxidation dynamics in strontium cobaltite

Understanding how water vapor interacts with transition metal oxides (TMOs) is critical for tailoring material properties to improve performance and enable new technologies. Despite extensive research efforts, atomic-scale mechanisms underpinning dynamic reactions and reaction-induced phase transitions remain elusive. Here, we use in situ environmental transmission electron microscopy to investigate how water vapor oxidizes vacancy-ordered SrCoO 2.5 at moderately elevated temperatures, demonstrating that water molecules can initiate oxidation more effectively than oxygen under comparable conditions. We discover a distinct “staging” behavior during the oxidation process: A fully ordered intermediate phase, SrCoO 2.75 , forms before transitioning into a near-perovskite SrCoO 3−δ . In addition, antiphase boundaries, originating at step terraces of SrTiO 3 , alleviate strain by creating reversible nanoscale “gaps” during lattice contraction under oxidation, providing a pathway for preserving structural integrity throughout redox cycling. This work provides atomic-level guidance for engineering TMOs by leveraging water vapor to control their redox behavior and tailor functional properties.

Science & Technology - Other Topics↗

DOE OSTI2025

University of Miami G-band Vapor Radiometer Calibration (UMGVR_CAL) Field Campaign Report

Cold-air outbreak (CAO) clouds in the Arctic are commonly mixed-phase (MP); however, the partitioning of the amount of ice and water in CAO clouds and precipitation is not always well observed. Understanding how cloud phases partition as a function of cloud life cycle is important for predicting snowfall rates, convective life cycle, and intensity at weather timescales. The partitioning into liquid versus ice also has radiative impacts that are consequential for climate. These concerns motivated the incorporation of an airborne G-band vapor radiometer (GVR) into an National Science Foundation-supported aircraft campaign named the Cold Air outbreak Experiment in the Sub-Arctic Region (CAESAR). The GVR is an upward-pointing passive microwave radiometer using four frequencies centered around the 183.31 GHz water vapor absorption line, displaced by +- 1, 3, 7, and 14 GHz. For context, The U.S. Department of Energy (DOE)’s Atmospheric Radiation Measurement (ARM) user facility operates a surface-based GVR at its North Slope of Alaska (NSA) site. The same GVR has been used previously for a field campaign in the southeast Pacific, where an offset was noticed between brightness temperatures (Tbs) measured under clear skies compared to those calculated from a radiative transfer model. To account for any calibration offsets to the Tbs, a request was made to DOE to allow the GVR to operate at ARM’s Southern Great Plains (SGP) observatory and enable comparisons between its measurements and those available at SGP. This request was granted, titled ‘UMGVR_CAL’, short for ‘UMGVR_Calibration’. From October 30 to November 10, 2023, the GVR was deployed to the ARM SGP site to take advantage of their regular, nearby radiosonde launches under clear-sky conditions. The latter were determined using the SGP total sky imagery data. The GVR brightness temperatures in these clear-sky conditions were compared to those calculated by a radiative transfer code (PAMTRA) based on the SGP radiosondes. During the campaign, four suitable clear-sky episodes could be used for the GVR calibration. While few in number, these proved to be enough to satisfy our goal.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Suppressing Phase Segregation and Improving Stability in Mixed-Halide Perovskites through Spinel Oxide-Directed Epitaxy

Mixed-cation mixed-halide perovskite compositions are essential for achieving the required bandgaps for high-efficiency multijunction photovoltaics, yet their stability remains limited by interfacial defects, phase segregation, and degradation. Here, we introduce spinel oxides as a new family of lattice-matched substrates that enable crystalline, phase-pure, compositionally-uniform, bromide-rich perovskite film growth. The effect of spinel oxides is two-fold: reducing defects at the bottom interface by templating film growth and inducing beneficial compressive strain through mismatch-dependent substrate-perovskite lattice coupling. Spinel oxide substrates facilitate growth of highly crystalline films and eliminate detrimental secondary phases across thicknesses. Using grazing incidence X-ray diffraction, X-ray fluorescence, cathodoluminescence–scanning electron microscopy, cryogenic photoluminescence, and density functional theory, we reveal that Mg-halide bonds at the bottom interface induce lattice mismatch-dependent compressive strain that suppresses halide segregation and further reduces defect formation. In addition, films grown on spinel oxides maintain over 87% of the perovskite phase after 12 h under 100% relative humidity, as monitored by in situ grazing incidence wide-angle X-ray scattering (GIWAXS), compared to less than 70% for control samples. This work extends lattice matching from vapor-deposited epitaxial semiconductors to solution-processed halide perovskites to establish a broadly applicable strategy for defect suppression, phase homogenization, and long-term stability. Based on the fundamental science explored here, we set the stage for the development of lattice-matched spinel oxide charge transport layers to be integrated into perovskite solar cells and other optoelectronic devices.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Nonparaxial propagation of an intense relativistic electron beam through dense media

An envelope equation is used to explore the propagation of a focused electron beam through dense conductive media like partially ionized high-pressure gas, metal vapor plumes from beam-target interactions, or low-density solid-phase targets. Envelope equations have been a most useful tool for predicting experimental results of beam propagation in gas, and they are refined for the general problem of propagation through a dense medium. The envelope equation is modified to account for the large beam divergence resulting from multiple scattering. The envelope code results are in qualitative agreement with published experimental data. Published by the American Physical Society 2025

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Online Molten Salt and Gas Monitoring Using Combined Spectroscopic Methods

The nonproliferation of nuclear material and the development of safeguards technologies to sample and analyze fuel salt is a challenge for molten salt reactor (MSR) developers. We seek online monitoring using combined spectroscopic methods of two distinct material phases from MSR’s. Molten salt transformed to aerosol phase allows for Light Induced Breakdown spectroscopy (LIBS) without adverse splashing (ARPA-E). Vaporized used nuclear fuel through chlorine-based volatility (CBV) allows for uranium separation based on boiling point differences

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2025

Electrified vapour deposition at ultrahigh temperature and atmospheric pressure for nanomaterials synthesis

Vapour-phase synthesis methods have shown promise for the scalable synthesis of nanomaterials and coatings. However, the vaporization of different precursors for the synthesis of a broad nanomaterial space, particularly at atmospheric pressure, while maintaining compositional and structural control of the final product is challenging. Here we report the generation of an ultrahigh-temperature atomic vapour at atmospheric pressure based on electrified heating, for the growth of multi-elemental nanomaterials and thin films. This process relies on a reactor design whereby solid-state precursors are vaporized within a semi-confined space beneath an electrified heater that can reach ~3,000 K. The proximity of the heater rapidly breaks down the bonds of metal salt precursors and decomposes them into an atomic vapour that expands into a high-temperature (>2,000 K), highly reactive and high-flux vapour (10 21 –10 22 atoms per cm 2 per second) that travels upwards in a directional flow. When mixed with entrained ambient gases, the highly reactive atomic species rapidly nucleate and grow into the desired final products, including alloys, oxides, sulfides and thin films, which can be deposited on a low-temperature substrate. This EVD approach can synthesize a broad range of functional nanomaterials at atmospheric pressure, including single-phase multi-elemental nanomaterials formed under thermodynamically non-equilibrium conditions.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Property Measurements of LiF-NaF-KF Molten Salts Doped with Corrosion Products and Oxygen

Measurements of thermophysical properties of molten salts are needed for modeling and simulation activities that support the development of molten salt reactor (MSR) technologies. Properties of interest including transition temperatures, phase behavior, heat capacity, density, volumetric thermal expansion, surface tension, viscosity, thermal diffusivity, thermal conductivity, and vapor pressure are being performed at Argonne. Results of these property measurements are suitable for use in evaluating reactor performance during startup and the early operating life of the reactor. Ingressions of oxygen and moisture into the fuel salt are expected to occur at different times during the operating life of the reactor due to system leaks, maintenance, and refueling activities. The presence of these environmental contaminants induces corrosion of structural materials. The introduction of corrosion-derived species, oxygen and moisture is expected to affect the physical and chemical properties of the salt and operation of the reactor. Previous work performed at Argonne evaluated the effects of fission product dopants on the thermal properties of eutectic LiF-NaF-KF (FLiNaK). Properties of FLiNaK are commonly used to represent those of fluoride-bearing fuel salts. Metallic corrosion products such as chromium and nickel ions together with dissolved oxygen are expected to affect system redox differently than the accumulation of fission products. Work summarized in this report was performed to measure the effects of corrosion products and dissolved oxygen on the phase transitions, and specific heat capacity of FLiNaK. Thermophysical property measurements were made using four salts that were prepared by doping aliquots of a eutectic mixture of FLiNaK with surrogate corrosion products. Controlled additions of CrF 3 and NiF 2 were used as surrogates for corrosion product contamination anticipated during extended reactor operations in which fuel salt is in contact with steel reactor components. Controlled additions of UF 4 from two sources containing known amounts of UO 2 at different concentrations were used to represent oxygen contamination. The phase transitions and specific heat capacities of the four salts were measured by using differential scanning calorimetry. Measurements were made at temperatures spanning the range of 500−900 °C, which is the expected operating range of MSRs. Measured property values were compared to values measured previously with eutectic FLiNaK without dopants. Differences between property values measured for the doped and non-doped salts were compared with the uncertainties of the measurements to determine the significance of the effect of corrosion products and oxygen on salt properties.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Property Measurements of LiF-NaF-KF Molten Salts Doped with Surrogate Fission Products

Measurements of molten salt properties including transition temperatures, phase behavior, heat capacity, density, volumetric thermal expansion, surface tension, viscosity thermal diffusivity, thermal conductivity, and vapor pressure are performed at Argonne. The properties of several fuel and coolant salts including eutectic LiF-NaF-KF (FLiNaK) have been measured. These properties are suitable for use in evaluating reactor performance during startup and early operating conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

Glovebox CFD Analysis: Low-Flow, Laminar CFD Analysis of Glovebox Ventilation and Humidity Transport in Ansys Fluent 2025 R1

There are gloveboxes that frequently exceed the 30% relative humidity level required for operations. These exceedances result in alternative operations needing to be utilized. This report documents a computational fluid dynamics (CFD) analysis performed to characterize airflow and humidity transport within a representative glovebox under nominal, low-flow conditions. The analysis focuses on establishing the flow regime, identifying transport-limited regions, and evaluating the implications of laminar flow on humidity removal. A single-phase, laminar flow model with a species transport model was used to represent air and water vapor mixing. Results demonstrate that, at the nominal flow rates, airflow is laminar with weak mixing, which will result in long residence times, tens of minutes long or more, in low-velocity regions. These conclusions suggests that humidity reduction is transport-limited. This analysis provides qualitative insight into airflow structure and humidity transport trends. In addition to characterization of glovebox airflow and humidity transport, results are intended to inform experimental validation and future transient modeling efforts.

42 ENGINEERING↗

DOE OSTI2024

Generalized Brunauer–Emmett–Teller Isotherm for Mixed-Gas Multilayer Adsorption Equilibria

Here, this work presents a rigorous thermodynamic framework to calculate mixed-gas multilayer adsorption equilibria from single-component isotherms and vapor–liquid equilibria. Named the generalized Brunauer–Emmett–Teller (gBET) isotherm, the newly formulated isotherm considers adsorbent surface heterogeneity, competitive adsorption on the monolayer, condensation–evaporation on the subsequent layers, and adsorbed phase nonideality for the monolayer and the subsequent layers. The monolayer adsorbed phase nonideality is tracked by using an area-based adsorption nonrandom two-liquid activity coefficient model. The adsorbed phase composition and corresponding nonideality in the subsequent layers are calculated at the dew point condition of the mixed gas with either an equation of state or an activity coefficient model for the vapor–liquid equilibria. The proposed model is validated with six single and three binary multilayer adsorption equilibrium systems, and the model results are compared against those from the classical BET isotherm for single-component adsorption and ideal adsorbed solution theory for mixed-gas adsorption equilibria.

09 BIOMASS FUELS↗

DOE OSTI2026

Flow Boiling Pressure Drop Characteristics of Next-generation Refrigerants in a Micro‑fin Copper Tube

This paper presents experimental frictional pressure-drop data for flow boiling of R-410A, R-134a, and next-generation alternatives R-454C, R-455A, R-1234yf, and R-1234ze(E) in a horizontal micro-fin copper tube. Tests were conducted over a range of mass fluxes and evaporation temperatures to characterize refrigerant-dependent two-phase pressure-drop behavior. The results show that frictional pressure gradient increased with mass flux and vapor quality and generally increased as evaporation temperature decreased, with liquid viscosity strongly affecting the observed trends. Among the evaluated correlations, the Goto et al. (2001) model gave the best overall agreement with the measurements before optimization. Further optimization of the Kuo and Wang (1996) and Goto et al. (2001) models reduced the overall mean absolute deviation to below 15%, with the optimized Goto (2001) model providing the most consistent predictions across all six refrigerants. The results support improved pressure-drop prediction and evaporator design for next-generation refrigerants in micro-fin tubes.

Hu, Yifeng [ORNL] (ORCID:0000000242875185)↗

DOE OSTI2025

The joys and jitters of high‐temperature calorimetry

Abstract High‐temperature calorimetry (HTC) originated in the 20th century as a niche method to enable measurements not easily accomplished with acid solution calorimetry, combustion calorimetry, vapor pressure, or EMF methods. Over time, HTC has evolved into a versatile approach to accurately quantify formation, phase transition, surface and interfacial enthalpies of a wide range of materials including minerals and refractory inorganic compounds. This evolution has been the result of numerous adjustments to experimental setups and procedures, followed by rigorous testing. The commercial availability and the scientific success of this technique have led to an increase in the number of laboratories applying HTC. However, the knowledge acquired by researchers over the past 70 years is scattered throughout the literature or only available as laboratory internal documentation and personal experience. This publication is a collaborative effort among several leading HTC laboratories to summarize and unify current state‐of‐the‐art HTC techniques and procedures. The text starts by summarizing various HT techniques that are commonly used for readers with an interest in HTC in general. It is then directed toward HTC users and includes a brief section on data evaluation procedures as well as a comprehensive compilation of reference data utilizing molten sodium molybdate and lead borate solvents. Finally, for experienced HTC users, an in‐depth discussion of some common difficulties and a discussion of uncertainties are presented.

Scharrer, Manuel [Navrotsky Eyring Center for Mate↗